Bubble mailer chill pack envelope

ABSTRACT

An inner thermal container, molded from an expanded polystyrene, seals in temperature sensitive materials with a cooling means for maintaining a low temperature. Inner and outer coatings provide additional thermal, vapor, and moisture insulation. The inner thermal container is inserted and sealed in a bubble wrap mailer envelope with layers of vapor and moisture proof thermal insulation.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present utility patent application claims the benefit of provisionalapplication No. 60/853,416 filed Oct. 23, 2006.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to mailing packaging and in particular toa combination temperature insulated and shock resistant mailer systemhaving an inner thermal container molded from an expanded polystyrenewhich seals in temperature sensitive materials with a cooling means formaintaining a low temperature, the inner thermal container being sealedin a bubble wrap mailer envelope with layers of vapor and moisture proofthermal insulation that is puncture resistant, together forming atemperature insulated, puncture resistant, and shock resistant mailersystem for transporting a temperature sensitive material maintained at acold temperature and protected from shock during transporting.Description of Related Art including information disclosed under 37 CFR1.97 and 1.98

The current packaging being used today isn't the most cost effectivepackaging due to the lack of package sizes for small shipments, such asindividual medical supply shipments and a lack of available packagingalternatives outside of packaging for large shipments of supplies from amanufacturer. Due to having only oversized packaging available, thepackaging for small medical shipments for individual use is often alarge percentage of the cost of the actual products being shipped.

Many temperature sensitive pharmaceutical and medical products useExpanded Polystyrene (EPS) containers because of its excellent thermalinsulation properties. Expanded polystyrene is the generic name forpolystyrene copolymers. Strongly relied upon in the pharmaceuticaldistribution industry, EPS is ideal for long distance shipment ofperishable items. EPS is highly resistant to heat/cold flow and thecellular structure of molded polystyrene is essentially impermeable towater.

Many temperature sensitive pharmaceutical and medical products use EPSbecause comparable packaging materials can rarely offer the same levelof thermal insulation. Strongly relied upon in the food distributionindustry, EPS is ideal for long distance shipment of perishable foods.

The cellular structure of molded polystyrene is essentially impermeableto water and provides zero capillary action. However, EPS may absorbmoisture when it is completely immersed due to its fine interstitialchannels within the bead-like structure. While molded polystyrene isnearly impermeable to liquid water, it is moderately permeable to vaporsunder pressure differentials. Vapor permeability is a function of bothdensity and thickness. Generally, neither water nor vapor affects themechanical properties of EPS.

For more than 50 years, the effectiveness of EPS has been proven innumerous packaging applications used by a wide variety of industries,from consumer product manufacturers and catalog shipping companies toaircraft parts. Lightweight EPS is ideal for these packagingapplications due to its physical properties, in particular itscushioning characteristics, dimensional stability and its thermal andmoisture resistance.

Custom-molded EPS interior packaging has been highly effective inprotecting sensitive electronic components, consumer goods and officeequipment. Its moldability allows interior packaging components to holdproducts snugly in place. High insulating properties and moistureresistance have made EPS a popular choice in the food packaging, medicaland pharmaceutical industries. EPS is also used to protect a myriad ofother products used for component assembly, during internal distributionand storage and delivery to the end user.

Prior art patents and published applications as listed below fail toprovide a reasonably inexpensive and highly effective means for shippingsmall quantities of temperature sensitive products for individual usage.

The prior art includes U.S. Pat. Nos. 5,129,519; 6,336,340; 7,106,202,6,776,747; 5,199,795; 5,316,149; 6,652,933; 5,009,319; 5,791,476;6,139,188; 4,620,633; 6,247,329; 6,223,551; 6,176,613; 4,925,029; andU.S. patent applications number US2005/0019511A1; and US2006/0289165A1.

What is needed is a cost effective, efficient, and effective system forshipping small quantities of temperature sensitive items, such asmedically related items shipped individually or in small quantities foruse.

BRIEF SUMMARY OF THE INVENTION

An object of the present invention is to provide a temperature insulatedshock resistant mailer system comprising in combination an outer bubblewrap mailer envelope and an inner thermal container as a cost effective,efficient, and effective system for shipping small quantities oftemperature sensitive items, such as medically related items shippedindividually or in small quantities for individual use.

A related object of the present invention is that the packaging of thepresent invention provides quality tested materials with advancedthermal insulation and shock resistant technology to insure the highestperformance levels throughout the shipment's journey through theharshest of environments.

Another object of the present invention is to provide a peel and sealstrip for permanent closure of the bubble wrap mailer envelope, which isthermally insulating, puncture resistant and water-repellant.

An added object of the present invention is to provide a gel ice packinside the inner thermal container using specially formulated,non-toxic, non-caustic refrigerants hermetically sealed in heavy-dutyand puncture-proof pouches for re-usable and economical cooling toextend shipping times.

In brief, an inner thermal container molded from an expanded polystyrene(E.P.S.) material (the generic term for polystyrene copolymers) seals intemperature sensitive materials with a cooling means for maintaining alow temperature and the inner thermal container is sealed in a bubblewrap mailer envelope with layers of vapor and moisture proof thermalinsulation that is puncture resistant, together forming a temperatureinsulated, puncture resistant, and shock resistant mailer system fortransporting a temperature sensitive material maintained at a coldtemperature and protected from shock during transporting.

The present invention provides a cost effective way to ship smallquantities of temperature sensitive materials, such as pharmaceuticalitems for individual users and is available in various sizes to meetshipping requirements for different applications. The present inventionprovides to the consumer (S-Value) savings per shipment unit.

An advantage of the present invention is that it will keep the worry outof shipping pharmaceutical products from being damaged or stolen due tothe double sealing with the outer bubble wrap mailer sealed envelope andsealed inner thermal container.

A related advantage of the present invention is that it is light weightbut still sturdy enough of to survive an impact from other packages manytimes bigger and heavier in their size.

One more advantage of the present invention is that it exceeds all priorthermal and package security mailing solutions in the pharmaceuticalindustry intended to cut down the cost of cold temperature packaging.

A further advantage of the present invention is that it brings togethermaterials made from highest thermal insulation and shock resistanttechnologies currently that are cost effective.

A significant advantage of the present invention is that it provideslower packaging costs providing (S-Value) cutting overhead shippingcosts on packaging and on shipping rates because it is an envelope.

A related advantage of the present invention is that it would provide(S-Value) savings to corporate and private industries shipping any Rxpharmaceuticals, vitamins, and other products that require temperaturesat a constant consistent cooled level to keep their product integrity.

Yet another advantage of the present invention is that it will reducethe waste going into the world's landfills as well as wasting the worldsnatural resources on a daily basis by providing a smaller size ofpackaging or a packaging alternative that was not previously available.

A major advantage of the present invention is that it insures thehighest performance levels for a package containing temperaturesensitive and fragile materials throughout the shipment's journeythrough the harshest of environments.

Another advantage of the present invention is that the lightweightmaterial saves on postage while the cushioned bubble lining envelope andinner thermal container shield the shipment from possible heat damage.

An added advantage of the present invention is that the foil laminatedlayer for the bubble wrap mailing envelope adds another level ofprotection and an added peace of mind knowing the product's integrity isnot at risk.

An ensuing advantage of the present invention is that shipping with thepresent invention is the most cost effective way to ship any Rx, vitaminproducts etc. to ensure or exceed coldest temperature requirementsmaintained throughout a length of 24-48 hours in transit.

One more advantage of the present invention is that it utilizes moldedfoams which are safe, clean, light-weight and not dangerous in any way.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

These and other details of the present invention will be described inconnection with the accompanying drawings, which are furnished only byway of illustration and not in limitation of the invention, and in whichdrawings:

FIG. 1 is an exploded perspective view of the temperature insulatedshock resistant mailer system of the present invention showing thecomponents of the inner thermal container aligned for assembly andaligned with the outer bubble wrap mailer envelope for insertiontherein;

FIG. 2 is a cross-sectional view taken through one surface of the outerbubble wrap mailer envelope showing the different layers;

FIG. 3 is a perspective view of the inner thermal container with the twohalves sealed together;

FIG. 4 is a perspective view of the sealed inner thermal containerinserted within the outer bubble wrap mailer envelope sealed therein.

DETAILED DESCRIPTION OF THE INVENTION

In FIGS. 1-4, a temperature insulated shock resistant mailer system 10comprising in combination an outer bubble wrap mailer envelope 30 and aninner thermal container 20.

In FIGS. 1 and 2, the outer bubble wrap mailer envelope 30 comprises atop sheet 31B and a bottom sheet 31A, each sheet 31 having bubble wrapmaterial 33 with insulating and shock absorbing air bubbles 36interconnected by plastic sheeting 34, as shown in FIG. 2. The twosheets 31A and 31B are heat sealed together to form a seam 32 around theperiphery of the two sheets with an opening 35 at one end. The top andbottom sheets 31A and 31B of bubble wrap provide a shock resistantcushion for contents of the bubble wrap mailer envelope as well asthermal insulation for the contents.

In FIG. 2, a temperature insulating moisture barrier and puncturebarrier, such as a combined layer of PERLITE 42 adhered to the bubblewrap 33 with a sealing MYLAR layer 41 to lock the layer of PERLITE inplace, are preferably provided on at least one surface of both sheets31A and 31B of the outer bubble wrap mailer envelope 30 so that the topand bottom sheets are water resistant and provided with further thermalinsulation and puncture resistance. Other layers may include a metalizedfoil laminated onto a strong co-extruded film, an outer coating ofMYLAR, or other types of barriers.

A means for sealing the envelope opening closed comprises an end flap 37folded over the envelope opening 35 onto the envelope body 38. The endflap 37 has an adhesive surface 39 to seal the end flap 37 closed overthe envelope body 38, as shown in FIG. 4. The adhesive surface 39 isnormally covered by a peel-off strip which is removed to adhere the endflap.

In FIGS. 1 and 3, the inner thermal container 20 is removably insertablewithin the outer bubble wrap mailer envelope 30, as shown in FIG. 4. Theinner thermal container 20 preferably comprises a shell, preferablyformed of light weight expanded polystyrene. The inner thermal container20 preferably comprises a pair of mating shells 21A and 21B of moldedlight weight expanded polystyrene. At least one, and preferably both, ofthe pair of mating shells has a recessed interior 25A and 25B to retainthe temperature sensitive material being shipped and the means formaintaining the temperature sensitive material at a cold temperaturewithin the recessed interior.

The means for sealing the inner thermal container closed to maintain thetemperature sensitive material at a cold temperature comprises matingoverlapping peripheral edges, comprising an flat outer edge 22A of a topshell 21A contacting a mating flat outer edge 22B of a bottom shell 21Bwith the top shell 21A overlapping a protruding ridge 24 extending upfrom the mating flat outer edge 22B of the bottom shell 21B forming anair tight seal between the pair of mating shells 21A and 21B. Anadhesive sealing tape 29 is adhered to and covers the mating peripheraledges of the pair of mating shells 21A and 21B, as shown in FIGS. 3 and4, to maintain the mating overlapping peripheral edges in a sealedcondition during transportation.

A thermal insulation coating 23A and 23B, preferably a layer of PERLITE,covers all wall surfaces of the interior chamber 25A and 25B to enhancetemperature retention. A layer of aluminum MYLAR over the layer ofPERLITE may be used to lock the layer of PERLITE in place. A vaporbarrier and thermal insulation layer 29 on the top shell 21A and thermalinsulation layer 28 on the bottom shell 21B, preferably a layer ofPERLITE coved by a layer of aluminum MYLAR, cover the exterior surfacesof the inner thermal container. Means for accessing the interiorchambers 25A and 25B preferably comprises the open two halves of theinterior chambers to install and remove the contents.

The inner thermal container 20 and outer bubble wrap envelope 30together forming a temperature insulated, puncture resistant, and shockresistant mailer system for transporting a temperature sensitivematerial maintained at a cold temperature and protected from shockduring transporting.

The vapor barrier and thermal insulation 28 and 29 covering an exteriorsurface of the inner thermal container may comprise metallic foil or acoating of reflective polyester laminated thereon.

The means for maintaining the temperature sensitive material at a coldtemperature within the interior chamber preferably comprises a gel icepack comprising specially formulated, non-toxic, non-causticrefrigerants hermetically sealed in a heavy-duty and puncture-proofpouch which is re-usable by re-freezing for each use to place the frozengel ice pack with the temperature sensitive material inside the innerthermal container 20.

The size of the inner thermal container is preferably 12.3″×11″×5″ with1.63″ thick walls for a universal size for the medical field, but may bemade in any of a variety of sizes as desired for specific or othergeneral uses.

The bubble wrap mailer envelope 30 is preferably 18″×22″ with a 3/16″ to5/16″ thick bubble wrap cushion to absorb shock and dampen vibrations.

In use, the present invention is used for shipping smaller scale singleorder shipments in the medical industry, such as Rx vial's (1-10 vials),Rx vials & needle kits, Rx Patches, Rx Vaccines etc. The presentinvention provides a temperature insulated shock resistant mailer systemas an economical packaging alternative for the entire pharmaceuticalindustry as a whole. The packaging of the present invention providesquality tested materials with advanced thermal insulation and shockresistant technology to insure the highest performance levels throughoutthe shipment's journey through the harshest of environments. The presentinvention provides a specialty product to the pharmaceutical industryfrom pharmaceutical manufacturers to pharmaceutical re-packagers and themedical community including private medical practices, walk-inpharmacy's, mail order pharmacy's, dental offices, hospitals, and anyother applications requiring shipments of small quantities andindividual temperature sensitive materials.

It is understood that the preceding description is given merely by wayof illustration and not in limitation of the invention and that variousmodifications may be made thereto without departing from the spirit ofthe invention as claimed.

1. A temperature insulated shock resistant mailer system comprising in combination: an outer bubble wrap mailer envelope comprising a top and a bottom sheet each of bubble wrap material generally heat sealed together around the periphery of the two sheets and having at least one peripheral envelope opening therein and a means for sealing the envelope opening closed, the top and bottom sheets of bubble wrap providing a shock resistant cushion for contents of the bubble wrap mailer envelope as well as thermal insulation for the contents; a temperature insulating moisture barrier and puncture barrier on at least one surface of both sheets of the outer bubble wrap mailer envelope so that the top and bottom sheets are water resistant and provided with further thermal insulation and puncture resistance; an inner thermal container removably insertable within the outer bubble wrap mailer envelope, the inner container comprising a shell of light weight expanded polystyrene, the inner thermal container having an interior chamber for containing a temperature sensitive material and a means for maintaining the temperature sensitive material at a cold temperature within the interior chamber, a thermal insulation coating covering all wall surfaces of the interior chamber to enhance temperature retention, a vapor barrier and thermal insulation covering an exterior surface of the inner thermal container, a means for accessing the interior chamber to install and remove the contents, and means for sealing the inner thermal container closed to maintain the temperature sensitive material at a cold temperature, the inner thermal container and outer bubble wrap envelope together forming a temperature insulated, puncture resistant, and shock resistant mailer system for transporting a temperature sensitive material maintained at a cold temperature and protected from shock during transporting.
 2. The system of claim 1 wherein the temperature insulating moisture and puncture barrier on at least one surface of both sheets of the outer bubble wrap mailer envelope comprises a layer of PERLITE.
 3. The system of claim 2 further comprising a layer of aluminum MYLAR over the layer of PERLITE locking the layer of PERLITE in place.
 4. The system of claim 1 wherein the thermal insulation coating covering all surface walls of the interior chamber of the inner thermal container comprises a layer of PERLITE.
 5. The system of claim 4 further comprising a layer of aluminum MYLAR over the layer of PERLITE locking the layer of PERLITE in place.
 6. The system of claim 1 wherein the temperature insulating moisture and puncture barrier on at least one surface of both sheets of the outer bubble wrap mailer envelope comprises a metalized foil laminated onto a strong co-extruded film.
 7. The system of claim 1 further comprising an outer coating of MYLAR around the inner thermal container shell to provide a vapor barrier and to enhance temperature retention within the inner thermal container.
 8. The system of claim 1 wherein the vapor barrier and thermal insulation covering an exterior surface of the inner thermal container comprises a layer of PERLITE to enhance temperature retention within the inner thermal container.
 9. The system of claim 8 further comprising a layer of aluminum MYLAR over the layer of PERLITE locking the layer of PERLITE in place.
 10. The system of claim 1 wherein the vapor barrier and thermal insulation covering an exterior surface of the inner thermal container comprises metallic foil laminated thereon.
 11. The system of claim 1 wherein the vapor barrier and thermal insulation covering an exterior surface of the inner thermal container comprises a coating of reflective polyester.
 12. The system of claim 1 wherein the inner thermal container comprises a pair of mating shells of molded light weight expanded polystyrene, at least one of the pair of mating shells having a recessed interior to retain the temperature sensitive material and the means for maintaining the temperature sensitive material at a cold temperature within the recessed interior, and the means for sealing the inner thermal container closed to maintain the temperature sensitive material at a cold temperature comprises mating overlapping peripheral edges forming an air tight seal between the pair of mating shells and an adhesive sealing tape adhered to and covering the mating peripheral edges of the pair of mating shells to maintain the mating overlapping peripheral edges in a sealed condition during transportation.
 13. The system of claim 1 wherein the means for sealing the envelope opening closed comprises an end flap folded over the envelope opening, the end flap having an adhesive surface to seal the end flap closed over the envelope, the adhesive surface normally covered by a peel-off strip which is removed to adhere the end flap.
 14. The system of claim 1 wherein the means for maintaining the temperature sensitive material at a cold temperature within the interior chamber comprises a gel ice pack comprising specially formulated, non-toxic, non-caustic refrigerants hermetically sealed in a heavy-duty and puncture-proof pouch which is re-usable by re-freezing for each use. 